Module 2

Best VTU Student Companion App You Can Get
DOWNLOAD NOW AND GET

Instant VTU Updates, Notes, Question Papers,
Previous Sem Results (CBCS), Class Rank, University Rank,
Time Table, Students Community, Chat Room and Many
More
CLICK BELOW TO DOWNLOAD VTU CONNECT APP

IF YOU DON’T HAVE IT
* Visit https://vtuconnect.in for more info. For any queries or questions wrt our
platform contact us at: support@vtuconnect.in
Download & Share VTU Connect App Now From Google Play Store
Additive Manufacturing 17ME82
MODULE 2: SYSTEM DRIVES, DEVICES AND ACTUATORS
System Drives and Devices: Hydraulic and Pneumatic motors and their features, Electrical
motors AC/DC and their features
Actuators: Electrical Actuators; Solenoids, Relays, Diodes, Thyristors, Triacs, Hydraulic and
Pneumatic actuators, Design of Hydraulic and Pneumatic circuits, Piezoelectric actuators,
Shape memory alloys.
An actuator is used to convert the energy of fluid back into the mechanical power. The
amount of output power developed depends upon the flow rate, the pressure drop across the
actuator and its overall efficiency. Thus, hydraulic actuators are devices used to convert
pressure energy of the fluid into mechanical energy.
Depending on the type of actuation, hydraulic actuators are classified as follows:
1) Linear actuator: For linear actuation (hydraulic cylinders)
2) Rotary actuator: For rotary actuation (hydraulic motor)
Hydraulic linear actuators, as their name implies, provide motion in a straight line. They are
usually referred to as cylinders, rams and jacks. The function of hydraulic cylinder is to
convert hydraulic power into linear mechanical force or motion. Hydraulic cylinders extend
and retract a piston rod to provide a push or pull force to drive the external load along a
straight-line path.
2.1 Hydraulic Cylinders:
2.1.1 Single-acting Cylinders:
A single-acting cylinder is simplest in design and consists of a piston inside a cylindrical

housing called barrel. On one end of the piston there is a rod, which can reciprocate. At the
opposite end, there is a port for the entrance and exit of oil. Single-acting cylinders produce
Department of Mechanical Engineering, ATMECE 1
force in one direction by hydraulic pressure acting on the piston during extension stroke. The
retraction is done either by gravity or by a spring.
2.1.2 Double-acting Cylinder:
(a)
(b)
Figure shows the operation of a double-acting cylinder with a piston rod on one side. To
extend the cylinder, the pump flow is sent to the blank-end port as in Fig.(a). The fluid from
the rod-end port returns to the reservoir. To retract the cylinder, the pump flow is sent to the
rod-end port and the fluid from the blank-end port returns to the tank as in Fig.(b).
2.2 Hydraulic Motors:

Depending upon the mechanism employed to provide shaft rotation, hydraulic motors can be
classified as follows:
1) Gear Motors
2) Vane Motors
3) Piston Motors
a) Axial piston type motors
b) Radial piston type motors
Gear motors are the least efficient, most dirt-tolerant and have the lowest pressure rating.
Piston motors are the most efficient, least dirt-tolerant and have high pressure ratings. Vane
and Piston motors can be fixed or variable displacement, but gear motors are available with
only fixed displacement.
2.2.1 Gear Motors:
Gear motors are very similar in design to the gear pumps, but motors are usually designed to
have a case drain port and a reversible direction of rotation. A gear motor develops torque
due to hydraulic pressure acting against the area of one tooth. There are two teeth trying to
move the rotor in the proper direction, while one net tooth at the centre mesh tries to move it
in the opposite direction. In the design of a gear motor, one of the gears is keyed to an output
shaft, while the other is simply an idler gear. Pressurized oil is sent to the inlet port of the
motor. Pressure is then applied to the gear teeth, causing the gears and output shaft to rotate.
The pressure builds until enough torque is generated to rotate the output shaft against the
load. Most of the gear motors are bidirectional. Reversing the direction of flow can reverse
the direction of rotation.
2.2.2 Vane Motors:
A rotary vane motor consists of circular chamber in which there is an eccentric rotor with
sliding vanes in the slots provided on the rotor. The rotor is placed eccentrically with the
housing. Fluid enters from the inlet port, rotates the rotor and thus torque is produced. The
displacement of a vane hydraulic motor is a function of eccentricity. The radial load on the
shaft bearing of an unbalanced vane motor is also large because all its inlet pressure is on one
side of the rotor.
Balanced Vane Motor:
The radial bearing load problem is eliminated in this design by using a double-lobed ring
with diametrically opposite ports. Side force on one side of bearing is cancelled by an equal
and opposite force from the diametrically opposite pressure port. The like ports are generally
connected internally so that only one inlet and one outlet port are brought outside. The
balanced vane motor is reliable open-loop control motor but has more internal leakage than
piston-type.
2.2.3 Piston Motors
Axial Piston Motors (Swash Plate-type):
In axial piston motors, the piston reciprocates parallel to the axis of the cylinder block. These
motors are available with both fixed and variable displacement feature types. They generate
torque by pressure acting on the ends of pistons reciprocating inside a cylinder block. The
motor, drive shaft and cylinder block are centred on the same axis. Pressure acting on the
ends of the piston generates a force against an angled swash plate. This causes the cylinder
block to rotate with a torque that is proportional to the area of the pistons. The torque is also a
function of the swash plate angle. If the offset angle is increased, the displacement and torque
capacity increase but the speed of the drive shaft decreases. Conversely, reducing the angle
reduces the torque capability but increases the drive shaft speed.
Bent-Axis Piston Motors:
This type of motor develops torque due to pressure acting on the reciprocating piston. In this
motor, the cylinder block and drive shaft mount at an angle to each other so that the force is
exerted on the drive shaft flange. Speed and torque depend on the angle between the cylinder
block and the drive shaft. The larger the angle, greater is the displacement and torque, and
results in smaller speed. This angle varies from 7.50 to 300. This type of motor is available in
two types, namely fixed-displacement type and variable-displacement type.
2.2.4 Electrical Motors:
The electric motors are used as the power source in a variety of mechatronic applications.
Therefore, electric motors often feature as the prime mover in a variety of driven systems.
They can either be classified on the basis of functionality or electromagnetic characteristics.
The difference in electric motors is mainly in the rotor design and the method of generating
the magnetic field.
The common classification of electric motors is as follows.
1) DC Motors
2) AC Motors
3) Stepper Motors
DC Motors:
Direct Current (DC) motors are used in a large number of mechatronic designs because of the
torque-speed characteristics achievable with different electrical configurations. DC motor
speeds can be smoothly controlled and they are reversible in most cases. Since DC motors
have high ratio of torque to rotor inertia, they respond quickly.
DC motors work based on the principle that “when a current carrying conductor is placed in a
magnetic field, it experiences a force. When a conductor moves in a magnetic field, an
electro-magnetic force is induced”.
In conventional DC motor, several coils of wire are mounted in slots on a cylinder of

magnetic material called armature. The armature is mounted on bearing and it is free to
rotate. It is connected to source of DC current through a switch mounted on the shaft and it is
called commutator.
When the electric current flows through the armature conductors placed in the magnetic field,
it experiences a force which causes the armature to rotate. As the armature rotates, the
commutator is reversed the current in each coil as it moves between field poles. As the
commutator are split, the current direction through coil reverses each time and thus, the
rotational torque is present all the time and the coil continues to rotate.
AC Motors:
An AC motor is an electric motor driven by an alternating current (AC). The AC motor

commonly consists of the following two basic parts.
• An outside stationary stator having coils supplied with alternating current to produce a
rotating magnetic field.
• An inside rotor attached to the output shaft producing a second rotating magnetic field.
AC induction motors:
The main parts in an AC induction motor are rotor and stator. The rotor construction looks
like a squirrel cage, hence, it is called squirrel cage induction motor. The rotor is made of
copper or aluminium bars and it fits into slots in end rings to form complete electrical
circuits.
A single phase motor has only one stator winding. This winding generates a field which
merely pulsates instead of rotating. When the rotor is stationary, the expanding and
collapsing stator field induces currents in the rotor. These currents generate a rotor field
opposite in polarity to that of the stator. The opposition of the field exerts a turning force on
the upper and lower parts of the rotor trying to turn 1800 from its position. Since these forces
are exerted through the centre of the rotor, the turning force is equal in each direction.
2.5 Relays:
Relays are electrically operated switches in which changing a current in one electrical circuit
switches a current on or off in another circuit. For the relay shown in the fig. when there is a
current through the solenoid of the relay, a magnetic field is produced which attracts the iron
armature, moves the push-rod, and so closes the normally open (NO) switch contacts and
opens the normally closed (NC) switch contacts.
Relays are often used in control systems; the output from the controller is a relatively small
current and a much larger current is needed to switch on or off the final correction element, in
such cases they are likely to be used in conjunction with transistors. Because relays are
inductances, they can generate a back voltage when the energising current is switched off or
when their input switches from a high to low signal. As a result, damage can occur in the
connecting circuit. To overcome this problem, a diode is connected across the relay. When
the back e.m.f occurs, the diode conducts and shorts it out.
2.6 Diodes:
The diode allows a significant current in one direction only. A diode can thus be regarded as
‘directional element’, only passing a current when forward biased, i.e. with anode being
positive with respect to cathode. If the diode is sufficiently reverse biased, i.e. a very high
voltage is applied, it will break down.
2.7 Thyristors:
The Thyristor, or silicon-controlled rectifier (SCR), can be regarded as a diode which has a
gate controlling the conditions under which the diode can be switched on. Figure shows the
thyristor characteristics. With the gate current zero, the thyristor passes negligible current
when reverse biased. When forward biased the current is also negligible until the forward
breakdown voltage is exceeded. When this occurs the voltage across the diode falls to a low
level, about 1 to 2V, and the current is only limited by the external resistance in the circuit.
Thyristors are widely used for switching high power applications.
2.8 Triacs:
The triac is similar to the thyristor and is equivalent to a pair of thyristors connected in
reverse parallel on the same chip. The triac can be turned on in either the forward or reverse
direction. Triacs are simple, relatively inexpensive, methods of controlling AC power.
2.9 Solenoids:
Solenoid is used for translating ON/OFF electrical signals to ON/OFF mechanical

movements and normally used as a linear actuator. A solenoid is made up of a coil with
movable iron core. The coil will have some voltage or current rating and may be AC or DC.
When the coil is energised, the core is pulled inside the coil; and the amount of force by
which the core is pulled mainly depends upon the number of coils and the amount of current
flowing in the circuit.
2.10 Piezoelectric Actuators:
The piezoelectric actuator achieves displacement by directly applying deformation of a solid,

and thus features a higher displacement accuracy, larger generation force and higher response
speed than other types of actuators. The piezoelectric ceramic material used in the
piezoelectric actuator generates electrical energy when it is subjected to mechanical energy
(piezoelectric effect) and generates mechanical energy when it is subjected to electrical
energy (inverse piezoelectric effect). These advantages have resulted in the piezoelectric
actuator being applied in many industrial equipment requiring precision position control, such
as ultrafine-movement stage of semiconductor exposure systems, precision positioning
probes and probes for scanning tunnel microscopy (STM) and atomic force microscopy
(AFM).
2.11 Shape Memory Alloys:
The material that remembers their original shape and return to it when heated, even if
apparent residual deformation was introduced below a certain temperature is called shape
memory alloy. The original shape can be set easily by heat treatment. The shape memory
alloy crystallographic structure changes between two phases, the low temperature
(martensite) and high temperature (austenite) phases.
Shape Memory Alloys as Actuators:
SMAs are useful for such things as actuators which are materials that change shape, stiffness,
position, natural frequency and other mechanical characteristics in response to temperature.
The SMA actuators are made as wire, spring or ribbon shape. It is able to produce extreme
forces from the viewpoint of volume to force ratio one-way SMA (one-way shape memory
effect) element can only provide force/displacement in one direction. A bias (return)
mechanism must be used if the actuator has to be returned to the original shape after the
heating phase.
HYDRAULIC CIRCUITS:
Control of a Single-Acting Hydraulic Cylinder:
The circuit has a filter, pump, pressure relief valve, a DCV and a spring return single acting
cylinder. In operation, with the cylinder in normally retracted position (under spring
pressure), when the valve is operated manually, the pressure port opens, the pump flow is
directed to the piston end of the cylinder and causes extension of cylinder. Once, the
extension is achieved, PRV opens-out and flow starts to pass through the PRV in the bypass
line. When the DCV is deactuated, the pressure port is blocked, and the oil from the piston
end of cylinder is routed to tank line. The cylinder starts retracting under spring pressure, and
the oil flows back to the tank.
Control of a Double-Acting Hydraulic Cylinder:
Four-way DCVs are commonly used to control the operation of double acting cylinders. Here
the valve shown in three positions: under extension (left envelope), neutral position (central
envelope) and under retraction (right envelope).
With the envelope in neutral position, the pump flow will continuously flow back to the tank
through the DCV. Hence with this, the actuator and the pump are not pressurised. When the
valve is actuated to the left envelope position, the pressure line is connected to the piston end
cylinder port, while rod-end cylinder port is directed to the tank line. Under the pump
pressure the cylinder extends and at the same time, the oil from the rod end freely flows back
to the tank through the DCV. At the end of the stroke until the DCV is deactivated, the flow
goes through the PRV. When the valve is actuated to the right envelope position, the pressure
line is connected to the rod-end port, and the piston-end port is connected to the tank line.
This causes cylinder retraction, with the oil from piston-end flowing freely back into the tank.
At the end of the stroke, the pressure builds up, the PRV opens out and the fluid flows
through the relief line.
Regenerative Cylinder Circuit:
Figure shows a regenerative circuit that is used to speed up the extending speed of a double-
acting hydraulic cylinder.
Note that the pipelines to both ends of the hydraulic cylinder are connected in parallel and
that one of the ports of the four-way valve is blocked. Fluid flows through the DCV via the
right envelope during retraction. In this mode, fluid from the pump bypasses the DCV and
enters the rod end of the cylinder. Fluid in the blank end drains back to the tank through the
DCV as the cylinder retracts.
When the DCV is shifted into its left envelope configuration, the cylinder extends. The speed
of extension is greater than the that for a regular double-acting cylinder because flow from
the rod end regenerates with pump flow to provide a total flow rate, which is greater than the
pump flow rate to the blank end of the cylinder.
Meter-in Circuit:
Cylinder speeds can be controlled with the use of Flow Control Valves (FCV). The use of
FCV to control the inlet flow to the cylinder hence the speed control is termed meter-in
control.
The operation of the cylinder to control its extension speed is explained with respect to two
valve positions. When the DCV is actuated manually to its right envelope mode, the flow
from the pressure line is directed to the piston-end port of the cylinder through the FCV. Note
that though there is a check valve, it is in closed position and the flow is forced to pass
through the metering orifice. Thus depending upon the orifice opening the flow is metered to
the inlet port. Hence the extending speed of the cylinder is controlled.
When the DCV is actuated manually to its left envelope mode, the flow lines are reversed.
The pressure line is directed to the rod-end port in the cylinder while piston-end port is
connected to the tank line. The cylinder starts retracting as the flow enters the rod-end port,
and at the same time the flow from the piston-end passes through the FCV. Note that the
check valve opens-out, thus the flow bypasses the orifice valve and passes through the least
resistance path, that is through the check valve without any restriction. Thus in retraction, the
cylinder moves back at its full design speed.
Meter-out Circuit:
The use of FCV to control the outlet flow from the cylinder hence its speed is termed as
meter-out circuit. The operation of the cylinder to control its extension speed is explained
with respect to two valve positions.
When the DCV is actuated manually to its right envelope mode, the flow from the pressure
line is directed directly to piston-end port of the cylinder. As the cylinder extends, the fluid
from the rod-end of the cylinder is forced out of the port. Since there is a FCV, the flow has
to pass through it. As there is a restriction to the flow through the FCV, the flow rate is
metered. Though the piston is pushing the fluid out with full force, it is resisted by the FCV
hence the extension speed is controlled. Note that though there is a check valve along with
the FCV, it is a one-way valve and remains closed when the fluid is being forced out of rod-
end port to the tank line.
When the DCV is actuated to the left envelope mode, the flow lines are reversed. The
pressure line is directed to rod-end port of the cylinder, while the piston-end port is connected
to the tank line. The fluid under pressure enters rod-end port through the FCV, but bypassing
the orifice. Instead it flows through the check valve, which now opens out due to favourable
direction of flow. There is no restriction of flow through the check valve in this direction,
hence full flow enters the cylinder, and it retracts with full design speed.

Module 2

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Module 2

Uploaded by

Copyright:

Available Formats

Best VTU Student Companion App You Can Get

DOWNLOAD NOW AND GET

CLICK BELOW TO DOWNLOAD VTU CONNECT APP

MODULE 2: SYSTEM DRIVES, DEVICES AND ACTUATORS

2.1 Hydraulic Cylinders:

2.1.1 Single-acting Cylinders:

A single-acting cylinder is simplest in design and consists of a piston inside a cylindrical

Department of Mechanical Engineering, ATMECE 1

2.1.2 Double-acting Cylinder:

2.2 Hydraulic Motors:

Department of Mechanical Engineering, ATMECE 2

2.2.1 Gear Motors:

2.2.2 Vane Motors:

Department of Mechanical Engineering, ATMECE 3

Balanced Vane Motor:

Department of Mechanical Engineering, ATMECE 4

2.2.3 Piston Motors

Axial Piston Motors (Swash Plate-type):

Bent-Axis Piston Motors:

Department of Mechanical Engineering, ATMECE 5

2.2.4 Electrical Motors:

The common classification of electric motors is as follows.

Department of Mechanical Engineering, ATMECE 6

In conventional DC motor, several coils of wire are mounted in slots on a cylinder of

An AC motor is an electric motor driven by an alternating current (AC). The AC motor

Department of Mechanical Engineering, ATMECE 7

Department of Mechanical Engineering, ATMECE 8

Department of Mechanical Engineering, ATMECE 9

Solenoid is used for translating ON/OFF electrical signals to ON/OFF mechanical

Department of Mechanical Engineering, ATMECE 10

2.10 Piezoelectric Actuators:

The piezoelectric actuator achieves displacement by directly applying deformation of a solid,

2.11 Shape Memory Alloys:

Department of Mechanical Engineering, ATMECE 11

Shape Memory Alloys as Actuators:

Control of a Single-Acting Hydraulic Cylinder:

Department of Mechanical Engineering, ATMECE 12

Control of a Double-Acting Hydraulic Cylinder:

Department of Mechanical Engineering, ATMECE 13

Regenerative Cylinder Circuit:

Department of Mechanical Engineering, ATMECE 14

Department of Mechanical Engineering, ATMECE 15

Department of Mechanical Engineering, ATMECE 16

You might also like